Cladding system

ABSTRACT

A panel ( 1 ) for use in cladding a wall ( 12 ) and comprising a rigid base member ( 2 ) having first and second opposed surfaces ( 3,5 ) with a step ( 4,6 ) provided in each of the surfaces so that in situ the panel ( 1 ) can overlap with neighbouring panels to form a substantially uniform and planar base sheet. The step ( 6 ) in the second surface has a recess ( 7 ) provided therein for receiving a shaped edge region of a first neighbouring panel in situ, and an edge region ( 8 ) of the base member ( 2 ) being shaped to be received by a recess of a second neighbouring panel in situ. One or more facing members ( 9 ) secured to one of the first and second surfaces ( 3,5 ).

[0001] The present invention relates to a cladding system and more particularly to panels for use in cladding a wall.

[0002] For many years there has been a trend in the construction industry towards cladding external walls with cladding panels to provide a more attractive finish than can be achieved with modern materials such as concrete and cement. Cladding is also used to provide a finish to timber walls, and to timber and metal frame structures. Cladding represents a much cheaper option than the building of a solid stone or brick wall and is also much quicker to complete than these traditional alternatives.

[0003] There is described in British Patent Application No. 2227765 a cladding panel which is adapted to be attached to a support frame secured to a wall, in overlapping relationship with the panels above it on the framework. The panels are secured to the framework by means of integral clips. If necessary, the cladding panels can be secured to the frame by riveting, bolting or screwing.

[0004] An obvious disadvantage with the system proposed in GB2227765 is the requirement for a framework attached to a wall and to which the panels can in turn be secured. This complexity adds to the cost of cladding and can in many circumstances be impractical.

[0005] According to a first aspect of the present invention there is provided a panel for use in cladding a wall and comprising:

[0006] a rigid base member having first and second opposed surfaces with a step provided in each of the surfaces so that in situ the panel can overlap with neighbouring panels to form a substantially uniform and planar base sheet, the step in the second surface having a recess provided therein for receiving a shaped edge region of a first neighbouring panel in situ, and an edge region of the base member being shaped to be received by a recess of a second neighbouring panel in situ; and

[0007] one or more facing members secured to one of the first and second surfaces.

[0008] Preferably, the base member is provided with means for securing the base member to a wall. More preferably, this means comprises one or more passageways extending through the base member from the first to the second surface. The passageways are arranged in use to receive screws, bolts, nails or other fixings. The passageway(s) extend through a region of the base member which in situ is hidden by an overlapping portion of a neighbouring base member.

[0009] Preferably, the base member comprises cement reinforced with wood filaments. However, other materials may also be used to form the base member.

[0010] In a preferred embodiment of the invention, the base member is elongate having a plurality of brick facing members secured to one of its surfaces, wherein in use the panel simulates a portion of a brick wall. Each brick facing member is dimensioned and secured to the base member so that one edge of the facing member is aligned with an edge of the base member, and a predefined gap exists between the edge of the brick facing member and the step of the face to which it is attached. When the panel is in situ, said gap is the gap between brick facing members secured to adjacent base members. This gap can be filled with grout to further simulate the appearance of a brick wall.

[0011] Other facing members such as stone members may alternatively be secured to the base member.

[0012] Preferably, the recess provided in the rise of one of the steps is substantially V-shaped, and the tapering edge region of the base member is also substantially V-shaped. More preferably, the recess and the tapered edge region are dimensioned so that in situ the fit between the tapered edge region and the recess is a loose fit This loose fit provides a space which is able to accommodate dirt and other debris and prevents these from causing a misalignment of neighbouring panels. The loose fit also prevents the base members from splitting or cracking which might occur if the fit is too tight. A loose fit also enables easy removal of panels from a wall.

[0013] A corner panel may be provided for cladding a corner section of a wall. The corner panel comprises two of the panels as described above, secured to one another at a right angle, or any other suitable angle.

[0014] According to a second aspect of the present invention there is provided a panel for use in cladding a wall and comprising:

[0015] 1) a substantially planar and rectangular rigid base member

[0016] having first and second opposed surfaces,

[0017] the first and second surfaces each being provided with a longitudinally extending step at substantially the same distance from opposite edges of the base member,

[0018] the steps being of substantially the same height and being displaced from each other such that the base member is thicker in its central region than at its edge regions,

[0019] a recess in the rise of the step provided in the second surface, and extending along the length of the step,

[0020] the edge region of the base member furthest from the step provided in the second face being shaped such that in situ the edge region is received by the recess in the base member of a neighbouring panel; and

[0021] 2) one or more facing members secured to the first or second face of the base member so as to overlie the step provided in the second face of the base member but not the step provided in the first face of the base member.

[0022] According to a third aspect of the present invention there is provided a method of cladding a solid wall using a multiplicity of panels according to the first or second aspect of the invention, the method comprising:

[0023] securing a first panel directly to the wall:

[0024] securing a second panel directly to the wall in overlapping relationship with said first panel; and

[0025] securing each further panel directly to the wall in sequence and in overlapping relationship with the preceding panel.

[0026] Preferably, each panel is attached to the wall by a screw, bolt, nail or other fixing which passes through a hole formed in the base member of the panel, into the wall. Preferably, each panel is oriented such that the fixing members are located above the facing members of the panel.

[0027] For a better understanding of the present invention and in order to show how the same may be carried into effect reference will now be made, by way of example, to the accompanying drawings, in which:

[0028]FIG. 1 illustrates schematically in cross-section a cladding panel according to an embodiment of the invention;

[0029]FIG. 2 illustrates schematically in vertical cross-section a series of cladding panels fixed to a solid wall; and

[0030]FIG. 3 illustrates corner panels forming part of a wall cladding system.

[0031] With reference to FIG. 1, a cladding panel suitable for cladding a solid wall will now be described. Whilst it is envisaged that the main use of these panels is for cladding an external wall, the panels may also be used for cladding internal walls and also for cladding other surfaces such as roofs and floors.

[0032] The cladding panel 1 comprises a solid and rigid base member 2 which is preferably formed of a cement based structural board reinforced with engineered wood filaments. This material may be for example Pyrok™ manufactured by Cape Calsil Systems Limited of Middlesex, England. A solid sheet having a rectangular cross section may be machined to provide the base member 1 illustrated in FIG. 1 or alternatively the structure may be pre-formed by suitably moulding the cement based material.

[0033] As will be apparent from the transverse cross-section illustrated in FIG. 1, the upper or first surface 3 of the base member 2 is provided with a step 4 at some predefined distance l from the topmost edge of the base member 2. The height of this step h is approximately one half of the thickness of the base member 2. The lower or second surface 5 of the base member 2 is also provided with a step 6 which again has a height h approximately equal to one half of the thickness of the base member 2. The step 6 in the lower surface 5 is located at the same distance l from the bottom-most edge of the base member 2 as the step 4 in the upper surface 3 is from the topmost edge.

[0034] Whilst the step 4 provided in the upper surface 3 is at a right angle to the planar surface of the base member 2, the step 6 provided in the lower surface 5 slopes backward into the rise of the step 6 so as to form a V-shaped recess 7 in the step 6. The topmost edge 8 of the base member 2 is tapered at substantially the same angle as the recess 7 in the step 6.

[0035] A series of rectangular facing blocks 9 (e.g. five) are secured to the upper surface 3 of the base member 2 using an adhesive (e.g. a gap filling weather resistant liquid adhesive and setting agent). In the example considered here, these blocks 9 are made of the same material as conventional building bricks and, when viewed from the front, have dimensions similar to those of conventional bricks. However, the thickness of the blocks 9 is only a fraction of the thickness of a conventional brick (e.g. 20% or 1.5 cm). The facing blocks 9 are secured to the upper surface 3 of the base member 2, above the step 6 formed in the lower surface 5 of the base member 1, with their bottom-most edges aligned with the bottom-most edge of the base member 1. A gap of predefined distance g exists between the topmost edge of the brick facing blocks 9 and the step 4 in the upper surface 3 of the base member 2. A similar gap g is provided between the brick facing blocks 9 attached to the base member 2.

[0036] A number of holes 10 extend through the base member 2 between the topmost edge of the base member 2 and the step 4 in the upper surface 3. For a panel 1 which is approximately 1 metre in length, two or three such holes 10 are provided, the holes 10 being equally spaced from one another. FIG. 2 illustrates how the fixing holes 10 are used to secure a series of panels 1 a to 1 c to a solid wall 12. The first panel 1 a is aligned with its longitudinal axis to the horizontal, with the fixing holes 10 lying above the brick facing blocks 9. Screws 13 are then inserted through the fixing holes 10 into the wall to secure the panel to the wall 12. Once the first panel la has been fixed to the wall 12, a second panel 1 c is located above the first panel 1 a in the same orientation. The panel 1 b is lowered until the tapered edge region 8 of the first panel 1 a is fully located within the recess 7 provided in the lower step 6 of the base member 2 of the second panel 1 b. It will be appreciated that in this position the second panel 1 b will be effectively held against the wall 12 and there is minimal risk of the panel falling 1 b off the wall. This is important as it minimises the danger to the worker fixing the cladding to the wall, who may be working at a substantial height above the ground. There is no need for the worker to hold the second panel 1 b with his hand while securing screws through the fixing holes in the second panel. In the same way, the third panel 1 c is secured in overlapping relationship with the second panel 1 b.

[0037] In a typical working environment such as a building site, it will be appreciated that significant amounts of dirt and debris are likely to be present. If the fit between the tapered edge region 8 of a lower panel and the recess 7 formed in an upper panel is too tight, dirt or debris may become trapped between the panels resulting in misalignment. By appropriately shaping the tapered edge of the base panels (the cross-section of FIG. 1 illustrates that the end of the tapered edge region is chamfered) a pocket 14 can be created for holding loose debris and dirt, thus preventing misalignment. The recess formed in the base member may also be shaped to provide such a recess. The Loose fit between the tapered edge and the recess also prevents excessive forces being exerted between the panels which might otherwise result in the base members splitting. A loose fit also facilitates easy separation of the panels if that is necessary.

[0038]FIG. 3 illustrates panels 15, 16 suitable for cladding a corner section of a building. The principles of the construction of the corner panel, and of the method of fixing the corner panel to a wall, will be evident in the light of the above description.

[0039] Embodiments of the present invention provide a cladding system which can be very easily put in place against any type of wall, especially a solid wall such as might be constructed from timber, concrete blocks, and the like. By using the fittings described above it is not necessary to provide any special framework to which the cladding panels are attached. Furthermore, the actual fixings, e.g. screws, are hidden once the cladding has been fully erected.

[0040] It will be appreciated by the person skilled in the art that various modifications may be made to the embodiments described above without departing from the scope of the present invention. 

1-11. (Cancelled)
 12. A panel for use in cladding a wall and comprising: a rigid base member having first and second opposed surfaces and first and second opposed edge regions, with a step provided in each of the surfaces so that in situ the panel can overlap with identical neighbouring panels to form a substantially uniform and planar base sheet, the step in the second surface having a recess provided therein for receiving a shaped edge region of a first neighbouring panel in situ, said first edge region of the base member being shaped to be received by a recess of a second neighbouring panel in situ; and one or more facing members secured to one of the first and second surfaces, the base member being dimensioned so that in situ said second edge region abuts the step in the first surface of said first neighbouring panel resulting in a loose fit arising between said recess and the received shaped edge region of the first neighbouring panel.
 13. A panel according to claim 12, wherein the base member is provided with means for securing the base member to a wall.
 14. A panel according to claim 13, wherein said means comprises one or more passageways extending through the base member from the first to the second surface, the passageways being arranged in use to receive screws, bolts, nails or other fixings.
 15. A panel according to claim 14, wherein said passageway(s) extends through a region of the base member which in situ is hidden by an overlapping portion of a neighbouring base member.
 16. A panel according to claim 12, wherein the base member comprises cement reinforced with wood filaments.
 17. A panel according to claim 12, wherein the base member is elongate having a plurality of brick facing members secured to one of its surfaces, and wherein in use the panel simulates a portion of a brick wall.
 18. A panel according to claim 17, wherein each brick facing member is dimensioned and secured to the base member so that one edge of the facing member is aligned with an edge region of the base member, and a predefined gap exists between the edge of the brick facing member and the step of the face to which it is attached.
 19. A panel according to claim 12, wherein said recess is substantially V-shaped, and the tapering edge region of the base member is also substantially V-shaped.
 20. A method of cladding a solid wall using a multiplicity of panels according to any one of the preceding claims, the method comprising: securing a first panel directly to the wall: securing a second panel directly to the wall in overlapping relationship with said first panel; and securing each further panel directly to the wall in sequence and in overlapping relationship with the preceding panel.
 21. A method according to claim 20, wherein each panel is attached to the wall by a screw, bolt, nail or other fixing member which passes through a hole formed in the base member of the panel, into the wall.
 22. A method according to claim 21, wherein each panel is oriented such that the fixing members are located above the facing members of the panel. 